Bondo?

[3800SERIESII]

Just came across this today. I was sanding part of the rear drivers side door to re-paint it and then wham, the sanding block went through. It was rusted from the inside out. I pulled some of the metal out with pliers. Should I fill with bondo?

[PLAGUE PHANTOM]

Your better off replacing the door.

[3800SERIESII]

I was also going through that scenario too. I can pick up one around here from a junkyard for about $75-100.

[harofreak00]

The chances of finding a door that doesn't have rust in that same spot is pretty unlikely. Even the 2000+ have the same problem.

[3800SERIESII]

That is true. Ill just try to bondo it. Ill buy a gallon for $15 and get some hardener. Cant really make it any worse. Ill check out some "how to" vids.

[sandrock]

You don't want to bondo that. Bondo will hold moisture and over time will rust away what is surrounding it. And since it's in an area that will jostle around a lot, a glob of bondo is not choice.

Best option is to at least look for a door that's in good shape.
2nd best option is to look for a door with at the very least a good door skin.
3rd best option is to patch weld new metal then bondo on top of that.

If you MUST fill it, use JB-Weld stick putty. Unlike bondo, it won't hold moisture. And unlike bondo, it isn't flexible so you will need to prep the area GOOD so it will get a good bite when it cures. It sands easy enough. Bondo on top of that for finishing.

FWIW, bondo or any body filler for that matter is only good for 1/4" buildup. Best at 1/16th-1/8th range.

[00Beast]

Bondo's gonna crack and fall off. Your best bet is to get some sheet metal and fix it properly. Anything else isn't gonna last.

[PLAGUE PHANTOM]

Every Bonneville I have seen in my local junkyard has not have any sort of door rust. Most have had just knicks and dents.

[harofreak00]

On the inside, not outside? Take a picture of your car in the same spot...

[PLAGUE PHANTOM]

Back door or front

[harofreak00]

Rear door

[3800SERIESII]

All of the moisture must have got in by that little breathing hole on the inside of the door. It is a shame too because the car sat in long moist grass for like nine months and it was minnesota so it didnt make it any better. I have already replaced two rusted brake lines because they were leaking and my fenders have lower through-rust. Its always something since this car was neglected for so long.

[Arrowhead]

Maybe go "Old School" with a metal patch panel riveted or spot welded and then some real body solder. After that..... you'll have an old fashioned "lead sled" ! (Some of my Michigan ancestors did that soldering for the "big three" back in the 40s & 50s)

http://www.eastwood.com/autobody/leadin ... 4AodohQAhg


http://www.google.com/search?q=body+sol ... e&ie=UTF-8

[3800SERIESII]

Haha, that is a good idea. it went through on the other side now, so it is a "full hole" now. My dad had already brought up the metal patch rivet idea, so that may be a reasonable option. Thanks for the input Arrowhead. Got a bunch of good ideas now.

[3800SERIESII]

are 92-99 Pontiac Bonneville doors interchangeable?

[00Beast]

As far as I know, the doors are the same, but the trim changed, not sure about the locator holes in the door skin itself (for the trim).

[3800SERIESII]

Okay, I thought so. It would be nice if the locator holes were in the same position. Otherwise, I will just stick to finding a 96-99 door.

[PaulyGXP]

You don't want to bondo that. Bondo will hold moisture and over time will rust away what is surrounding it. And since it's in an area that will jostle around a lot, a glob of bondo is not choice.

Best option is to at least look for a door that's in good shape.
2nd best option is to look for a door with at the very least a good door skin.
3rd best option is to patch weld new metal then bondo on top of that.

If you MUST fill it, use JB-Weld stick putty. Unlike bondo, it won't hold moisture. And unlike bondo, it isn't flexible so you will need to prep the area GOOD so it will get a good bite when it cures. It sands easy enough. Bondo on top of that for finishing.

FWIW, bondo or any body filler for that matter is only good for 1/4" buildup. Best at 1/16th-1/8th range.

I agree with this. Find yourself a door! Pretty sure a 96-99 door would fit as well, just have to swap the moulding so it matches yours

[3800SERIESII]

On top of it. Been calling the local auto salvage places. Probably wont find a door in my color since it is not very abundant. But I am sure I will come up with a decent one in the next month.

[LeSabre in Buffalo]

Since you're repainting anyhow, just repaint the new to you door.